Installation Operation Maintenance - VariTrane Pneumatic ... · Installation/ Operation Maintenance...

Installation/OperationMaintenance

VariTrane™

Pneumatic Controls

VAV-SVX02B-ENMarch 2002

VAV-SVX02B-EN

Thermostat Selectionand LocationIn general, both one- and two-pipethermostats have a gain of 2.5 psi perdegree Fahrenheit, unless specialthermostats are used that provide adifferent gain. The major differencebetween them is that a one-pipethermostat is considered a low-capacity thermostat and a two-pipethermostat is considered a high-capacity thermostat.When selecting between one-pipe andtwo-pipe thermostats consider thefollowing:

Use one-pipe thermostat when:

� tubing runs are less than 50 feet fromthermostat to controller.

� a single thermostat will control nomore than three controllers.

� slower response is desired from thethermostat.

Use two-pipe thermostat when:

� tubing runs exceed 50 feet fromthermostat to controller.

� a single thermostat will control four ormore controllers.

� high capacity air is required due torestrictions in the air line.

Thermostat Piping

The two-pipe thermostat (Figure 1)includes a restrictor (internally). Attachsupply air line and output pressure(branch) line to the thermostat.The one-pipe thermostat (Figure 2)requires an external restrictor tee.Connect main air supply to restrictedleg of restrictor tee. Connect branch linefrom restrictor tee to the thermostat.

Figure 1–Two-Pipe Remote Thermostat (Reverse-Acting)

Thermostat

Figure 2–Typical One-Pipe Thermostat (Reverse-Acting)

2

Tee

20

(137.9)15

(103.4)

S

Two-PipeRemote-Mounted

T-Stat(Reverse-Acting)

(137.9)20S

TeeRestrictor

Tee

Restricted Leg

FanP.E.

Switch–1(N.O.)

9 PSI(62.06 kPa)

One-PipeRemote-Mounted

T-Stat(Reverse-Acting)

3VAV-SVX02B-EN

Thermostat

Specifications

TP970 Series Pneumatic T-statsMaximum Safe Air Pressure:25psi (172 kPa)Maximum Safe Air Temperature:150°F (66°C)

Throttling Range:2–10°F (1–5°C)

Gain:2.5 psi/°F Adjustable

Operation

Pneumatic thermostats modulateoutput air pressure in response to roomair temperature. Pneumatic thermo-stats fall into two categories: direct-acting or reverse-acting. This sectiondescribes how thermostat outputpressure responds to changes in roomtemperature.Figure 3 graphically illustrates therelationship between roomtemperature and output pressure of adirect-acting thermostat. The graph inFigure 3 shows that as the roomtemperature increases, so does theoutput pressure of the thermostat.

Figure 4 illustrates the pressure/temperature characteristics for areverse-acting thermostat. As roomtemperature increases, the thermostatoutput pressure decreases.

A thermostat in proper working orderwill be able to output a pressureranging from approximately .5 psi tosupply air pressure depending ondistance from indicated setpoint.

Figure 4–Reverse-ActingThermostat Response

Out

put

Pres

sure

Input Input TemperatemperatureFigure 3–Direct-ActingThermostat Response

Out

put

Pres

sure

Input Temperatemperature

VAV-SVX02B-EN

Installation and OperationThe reversing relay is a proportional,non-bleeding device for use in pneu-matic control systems where a propor-tional signal from a controlling devicemust be reversed (see Figure 5). Themost common use of the reversingrelay is to change the action of apneumatic thermostat.Figure 5–Pneumatic Reversing RelayTrane Part No. RLY-755

Reversing Relay

Figure 6–Reversing Relay Connections

The reversing relay requires threepiping connections: main/supply air,input signal air, and output branch air(see Figure 6). The branch line pressuredecreases in direct proportion to anincrease in the input signal pressureand vice-versa. The input signal is alsoamplified, thereby minimizing anypneumatic line transmission lag(see Figure 7).Input pressure to the relay and outputpressure to the PR should always addup to a constant, which is usually setbetween 16 and 25 psi. For example,with a constant of 18, six-pound inputsignal will result in a 12 pound branchsignal. A bias adjustment screw isprovided to retard or advance the outsignal.

4

Figure 7–Reversing Relay Characteristics

20(137.9)

SOutputBranch

InputBranch

ReversingRelay

B

M

S

9 PSI In(62.06 kPa)

9 PSI Out(62.06 kPa)

15

15

12

3

3

6

Input Pressure Signal

Out

put B

ranc

h Pr

essu

re

Inc.

Inc.

5VAV-SVX02B-EN

Reversing Relay

Calibration

By using the “bias” adjustment on therelay, the factory-set 8.0–9.0 “cross-over” can be changed. To recalibrate,the relay should be connected asillustrated in Figure 8.

Figure 8–Recalibrating Reversing Relay

If the new desired “cross-over”pressure is 11.0 psi, this must be appliedto port #3 by adjusting the pressureregulator. The “bias” adjustment is thenturned until 11.0 psi is obtained on theoutput gage. Turning the “bias” adjust-ment “CW” increases the output;“CCW” decreases it.This 11.0 psi “cross-over” would yieldthe following operational chart:

Specifications

Maximum Pressure:30 psigConnections:3/16" (4.& mm) nipples for ¼" (6.4 mm) ODpolyethylene tubing

Air Consumption:0.5 SCFH (.236 L/M) @ 20 psig

Material:ABS

Weight:3 ½ oz

Chart

Input: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20Output: 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

New Cross-over pressure

BiasAdjustment

Screw

Gage

M

1

C

3

MPressureRegulator

Ambient Limits:+40°F/+120°F operating (+4°C/+49°C)

Mounting:In-line via air connections

Factory Settings:9 psig in./9 psig out and 8 psig in./8 psigout

Bias Adjustment:+/-15 psi

VAV-SVX02B-EN

Model 3011The model 3011 Pneumatic VolumeRegulator (PVR) is capable of operatingwith normally-open or normally-closedair valves and can operate with eitherdirect-acting (DA) or reverse-acting(RA) thermostats.

Figure 9–Acceptable Installation Positions

Installation

1. Attach bracket either vertically or horizontally to the illustration surface. Horizontalis preferred, vertical is acceptable, any other position is not acceptable (see Figure 9).

2. Insert controller into its bracket. Controller may be face up, face down, face left, orface right. The controller LO and HI stat delta P must be calibrated in the sameposition that it is mounted.

Connections

Figure 10 illustrates a typical piping diagram of a normally-open or normally-closed unit.

Figure 10–Typical Piping Diagram of Normally-Open or Normally-Closed Unit

Selecting Direct- or Reverse-Acting Thermostat (3011)

The model 3011 PVR must be calibrated to operate with either a direct-acting orreverse-acting thermostat. The control must also be changed when used with anormally-open or normally-closed air valve.

Model 3011—PneumaticVolume Regulator

6

RCRCR

HI

LO

Airflow Sensor

Actuator

DAMPER

S20

M

B

H

G

NC

N CN CI

RESET SPAN

LO STAT

NI RCN RCR

HI STAT

∆P

T

∆P

S20

Normally-Open Unit orNormally-Closed Unit

VolumeRegulator

RestrictorTee

One-PipeRemote-Installed

T-Stat

Restricted Leg

7VAV-SVX02B-EN

Use the following procedure to set-up the PVR:1. Select damper action (NO or NC). Loosen damper selection switch screw and align to either the NO or NC pointer with damper

pointer and tighten screw.2. Now determine the type of thermostat that will be used. If a direct-acting thermostat is used, the reset start pressure is typically

8 psi. If a reverse-acting thermostat is used, the reset start pressure is typically 3 psi (see Figure 11).

3. With an accurate gage (0-10 psi) connected to port “G”, regulate the thermostat pressure to port “T” to desired start point pressure.

4. Adjust reset start to indicate 0 psi on port “G” and continuing adjusting to indicate a pressure slightly higher than 0 psi, (i.e., 0.1 psi).


Adjusting the Reset Span (3011)

The reset span is factory-set at 5 psi. This is the thermostat pressure difference from which the PVR delivers flow from minimumto maximum setpoints. This range is not normally changed unless a special control scheme is used where control operationmust be changed.To field adjust a different reset span, follow these steps:

1. Connect an accurate gage to port “G”.

2. Apply 20 psi to port “T”.

3. Adjust reset span to indicate the desired span on port “G” (see Figure 12).

4. LO-stat and HI-stat delta P must now be readjusted (see following calibration procedure)Figure 12–Adjusting Reset Span

Figure 11–Adjusting Reset Start

I N C R

Adjust to obtain 0–0.1 psi at port G

IN C RNO

NC

M

B

DAMPER

G

RESET SPAN

HI STAT ∆P

LO STAT ∆P

RESET START

psi

0 10

Connect Hand Pump

0–20 psiHandpump

Input desired LO statpressure at t-stat port

Connect 0–10 psi Gage

Factory-set at 5 psiAdjustable (0–10 psi)

NOTE: The arrows on the damper selector must be aligned exactly or the range of the controller will be limited .0 psi

CRCRC

100

PSI

DAMPER

NO

M

B

H

I N CN C

G

NC

Adjust to obtain desired reset span

Apply 20 psi

RESET STARTLO STAT

RESET SPAN

RR

RCRCRI N CN C

HI STAT

P

T

PP

VAV-SVX02B-EN

CalibrationProcedures

Calibration Procedure (Steps 1–4 apply to all thermostat models)

1. Be sure the PVR is installed correctly and that all connections are hooked up to the proper ports. See Figure 9 for unit application.

2. Remove the caps on the tees which are connected to the lines to the flow sensor. Connect a 0–2" magnehelic gage to monitorflow sensor delta P. The higher-pressure port is further upstream on the air valve inlet.

3. Remove the thermostat line and connect a hand pump with a 0–20 psi gage to port “T”.

4. Tee a 0–20 psi gage in the line from port “B” on the volume regulator to the air valve actuator.

Figure 13–Connections of Direct/Reverse-ActingThermostat with Normally-Open Valve

Figure 14–Connections of Direct/Reverse-ActingThermostat with Normally-Closed Valve

8

Direct-Acting Thermostat(See Figure 13 for properconnections)

5. Set port “T” at 0 psi.

6. Monitor the delta P andadjust the LO-stat mini-mum) adjustment todesired minimum.

7. Set port “T” input at 16psi or greater with thehand pump.

8. Monitor the delta P andadjust the HI-stat (maxi-mum) adjustment todesired maximum flow. Ifthe actuator pressure isless than 3 psi, the airvalve is wide open andduct pressure mustincrease to increase flow.


10.Monitor the minimumflow delta P. If it is notcorrect, adjust the LO-statadjustment knob.

Direct-Acting Thermostat(See Figure 14 for properconnections):


6. Monitor the delta P andadjust the LO-stat (mini-mum) adjustment todesired minimum.

7. Set port “T” input at16 psi or greater with thehand pump.

8. Monitor the delta P andadjust the HI-stat(maximum) adjustmentto desired maximum flow.If the actuator pressure isgreater than 13 psi, the airvalve is wide open and ductpressure must increase toincrease flow.



Normally-Open Valve Normally-Open Valve

Reverse-Acting Thermostat(See Figure 13 for properconnections):


6. Monitor the delta P andadjust the LO-stat delta P(maximum) adjustment todesired maximum. If theactuator pressure is lessthan 3 psi, the air valve iswide open and ductpressure must increase toincrease flow.

7. Set prot “T” to 16 psi

or greater with thehand pump.

8. Monitor the delta P andadjust the HI-stat (mini-mum) adjustment todesired minimum flow.


10.Monitor the maximumflow delta P. If it is notcorrect, adjust the LO-statadjustment knob.

Reverse-Acting Thermostat(See Figure 14 for properconnections):


6. Monitor the delta P andadjust the LO-stat delta P(maximum) adjustment todesired maximum flow. Ifthe actuator pressure isgreater than 13 psi, the airvalve is wide open andduct pressure mustincrease to increase flow.

7. Set prot “T” to 16 psior greater with thehand pump.

8. Monitor the delta P andadjust the HI-stat (mini-mum) adjustment todesired minimum flow.



0–2' Magnahelic Gage

CRCRC

LO

HI

Normally-Open Unit

Airflow Sensor

LO

Actuator

HI

NC

DAMPER

NO

M

20S

G

I N CN C

B

H

Connect Hand Pump


Apply 20 psi

HI STAT PP

LO STATRESET START

P

T

PSI

0 10

Handpump0–2 psi

VolumeRegulator

CRCRC

0–2' Magnahelic Gage

LO

HI

Normally-Closed Unit

Airflow Sensor

LO

Actuator

HI

S20

NC

DAMPER

B

M

NO

H

G

I N CN C


Connect Hand Pump

Apply 20 psi

LO STATRESET START

I N RCN RCR

HI STAT

P

P

T

PSI

0 10

0–2 psiHandpump

VolumeRegulator

VAV-SVX02B-EN 9

Specifications (3011)

Differential Pressure Range:0 to 1.0 in. wgMinimum Setpoint Range:0 to 1.0" H2O

Maximum Setpoint Range:minimum to 1.0 in. wg

Operating Static Range:0.25–6.0 in. wg


Normal Supply Air Pressure:20.0 psi

Minimum Supply air Pressure:15.0 psi

Maximum Supply Air Pressure:30.0 psi

Average Supply Air Consumption:28.8 scim at 20 psi

Thermostat Pressure Input Range:Adjustable 0–10 psi band from 0–20 psi

Reset Start Point Range:0–10 psi

Reset Span Range:0–10 psi

Maximum Safe Thermostat Input:30 psi (closed chamber)

Operating Temperature:+40/+120°F

Storage Temperature:-40/+140°F

Main, Thermostat, Actuator and StaticPick-up Connections:.250 O.D.

VAV-SVX02B-EN10

Model 3501The model 3501 Pneumatic VolumeRegulator (PVR) is capable of operatingwith normally-open or normally-closedair valves and can operate with eitherdirect-acting (DA) or reverse-acting(RA) thermostats.

Adjusting the Reset Span (3501)

The reset span is factory-set at 5 psi.This is the thermostat pressure differ-ence from which the PVR deliversflow from minimum to maximumsetpoints. This range is not normallychanged unless a special controlscheme is used where controloperation must be changed.To field adjust a different reset span,follow these steps:

1. Connect an accurate gage to port “G”.

2. Apply 20 psi to port “T”.

3. Adjust reset span to indicate thedesired span on port “G”.

4. LO-stat and HI-stat delta P must nowbe readjusted (see followingcalibration procedure).

Installation1. Attach bracket either vertically or

horizontally to the installation surface.Horizontal is preferred, vertical isacceptable, any other position isnot acceptable.

2. Insert controller into its bracket.Controller may be face up, face down,face left, or face right. The controllerLO and HI stat delta P must becalibrated in the same position that itis installed.

Selecting Direct- or Reverse-ActingThermostat (3501)

The model 3501 PVR must be calibratedto operate with either a direct-acting orreverse-acting thermostat. The controlmust also be changed when used witha normally-open or normally-closedair valve.Use the following procedure to set-upthe PVR:

1. Select damper action (NO or NC).Loosen damper selection switchscrew and align to either the NO orNC pointer with damper pointer andtighten screw.

2. Now determine the type of thermostatthat will be used. If a direct-actingthermostat is used, the reset startpressure is typically 8 psi. If a reverse-acting thermostat is used, the resetstart pressure is typically 3 psi.

3. With an accurate gage (0–30 psi)connected to port “G”, regulate thethermostat pressure to port “T” to10.5 psi.

4. Adjust reset start to indicate 2.5 psi onport “G”


VAV-SVX02B-EN 11

CalibrationProcedures

Calibration Procedure (Steps 1–4 apply to all thermostat models)

1. Be sure the PVR is installed correctly and that all connections are hooked up to the proper ports.

2. Remove the caps on the tees, which are connected to the lines to the flow sensor. Connect a 0–2" magnehelic gage to monitorflow sensor delta P. The higher-pressure port is further upstream on the air valve inlet.

3. Remove the thermostat line and connect a hand pump with a 0–20 psi gage to port “T“.

4. Tee a 0–20 psi gage in the line from port “B” on the volume regulator to the air valve actuator.

Direct-Acting Thermostat5. Set port “T” at 0 psi.

6. Monitor the delta P andadjust the LO-stat(minimum) adjustment todesired minimum.

7. Set port “T” input at16 psi or greater withthe hand pump.

8. Monitor the delta P andadjust the HI-stat(maximum) adjustment todesired maximum flow. Ifthe actuator pressure isless than 3 psi, the airvalve is wide open andduct pressure mustincrease to increase flow.



Reverse-Acting Thermostat5. Set port “T” at 0 psi.

6. Monitor the delta P andadjust the LO-stat delta P(maximum) adjustment todesired maximum. If theactuator pressure is lessthan 3 psi, the air valve iswide open and ductpressure must increaseto increase flow.


8. Monitor the delta P andadjust the HI-stat(minimum) adjustmentto desired minimum flow.



Normally-Open Valve

Direct-Acting Thermostat5. Set port “T” at 0 psi.

6. Monitor the delta P andadjust the LO-stat(minimum) adjustmentto desired minimum.

7. Set port “T” input at16 psi or greater withthe hand pump.

8. Monitor the delta P andadjust the HI-stat(maximum) adjustment todesired maximum flow. Ifthe actuator pressure isgreater than 13 psi, the airvalve is wide open and ductpressure must increase toincrease flow.



Normally-Closed

Reverse-Acting Thermostat5. Set port “T” at 0 psi.

6. Monitor the delta P andadjust the LO-stat delta P(maximum) adjustment todesired maximum. If theactuator pressure isgreater than 13 psi, the airvalve is wide open andduct pressure mustincrease to increase flow.


8. Monitor the delta P andadjust the HI-stat(minimum) adjustment todesired minimum flow.



VAV-SVX02B-EN12


Differential Pressure Range:0 to 1.0 in. wgMinimum Setpoint Range:0 to 1.0" H2O

Maximum Setpoint Range:minimum to 1.0 in. wg

Maximum Setpoint Range:6.0 in. wg

Normal Supply Air Pressure:20.0 psi

Minimum Supply air Pressure:15.0 psi

Maximum Supply Air Pressure:30.0 psi


Output Sensitivity:5 psi/.02

Average Supply Air Consumption:43.2 scim at 20 psi

Reset Start Point Range:0–10 psi

Reset Span Range:0–7 psi

Operating Temperature:+40/+120°F

Storage Temperature:-40/+140°F

VAV-SVX02B-EN 13

MCP-3631—RotaryPneumatic Damper Actuator

Description:

Rotary actuators mounts to a standard½" diameter shaft by a locking collarand bushing.Models:

MCP-3631-5000 8–13 psi range(55–90 kPa) Normally-Closed operationMCP-3631-8000 3–8 psi range(21–55 kPa) Normally-Open operation

Installation Method:

Slide collar onto shaft. Slide actuatoronto shaft noting directional rotation.Slide bushing onto shaft into actuator,aligns actuator with damper, lockcollar and bushing set screws, andinstall bracket.Maintenance:

No routine maintenance is required.

Specifications:

Effective Area:8 sq in. (52 sq cm)Normal Rotation:100 deg

Supply Pressure:0 to 20 psig (138 kPa) operating30 psig (207 kPa) maxSpring Ranges:Retracted/extended Torque(Based on 0 & 20 psi applied)8–13 psi (55–90 kPa);68/59 in. lbs (8/7 Nm) @ 90 deg

3–8 psi (21–55 kPa);25/102 in. lbs (3/12 Nm) @ 90 deg

Supply Connection:3/16" (5 mm) nipple for ¼" (6 mm)OD polyethylene tubing

Material:Body Glass-filled nylonDiaphragm Neoprene

Weight:1.5 lbs (0.68 kg)

Ambient Limits:Operating -20°F–120°F (-29°C–49°C)Shipping -40°F–140°F (-40°C–60°C)

MCP-3631—RotaryPneumatic Damper Actuator

VAV-SVX02B-EN14

Constant Volume Dual-DuctCalibration (3011)This calibration procedure is used whena constant volume of air must bemaintained through a unit. On a dual-duct unit, a constant-volume dischargesensor is used to measure the airleaving the unit. The PVR controlling to aconstant-volume of air leaving the unituses the discharge sensor to maintainthe specified cfm.

This PVR does not require a thermostatconnected to the PVR.

The following procedure must be usedwhen calibrating a constant-volumedual-duct unit. See Figure 15 for atypical piping diagram.

1. Set t-stat to full heat.2. Set LO thermostat (maximum) to the

desired maximum flow on theheating deck.

3. Set t-stat to full cool.4. Set HI thermostat (minimum) to

the desired minimum flow on theheating deck.

5. Set LO thermostat adjustment knobon cooling deck (CV deck) to desiredconstant-volume.

6. Exercise the system to check flowsfor proper operation.

Figure 15–Typical Constant-VolumeDual-Duct Piping Diagram

Constant-Volume Dual-DuctCalibration (3011)

VAV-SVX02B-EN 15

Thermostat Range: 3–8 psiHeating Valve = 5 psi rangeThermostat Range: 8–13 psiCooling Valve = 5 psi rangeApproximately 1000 cfm divided by 5 psi =200 cfm/1b*

*Due to the relationship between velocitypressure and cfm; for both the cooling andheating PVR, a linear relationship betweencfm and psi does not exist.

To obtain a unit minimum cfm of 400 cfm, theheating deck volume regulator must have itsthermostat range changed from 3–8 psi to4–9 psi. This is adjusted by changing the “resetstart” point from 3 psi to approximately 4 psi.

The cooling deck volume regulator must have itsthermostat range changed from 8–13 psi to7–12 psi. This is adjusted by changing the “resetstart” point from 8 psi to approximately 7 psi.

By overlapping the thermostat spring ranges, wewere able to have 0 cfm minimum settings onboth the heat and cool deck and still maintain therequired unit minimum cfm of 400 cfm.

The calibration of the PVR is the same as thenormal calibration procedures previouslydescribed in this manual.

Figure 17–Example

Variable-Air-Volume Dual-Duct Calibration (3011)

Figure 16 is a typical piping diagram ofa VAV dual-duct unit. The unit has athermostat piped to both pneumaticvolume regulators (PVR) which willoperate the heating deck from athermostat signal of 3–8 psi. The coolingdeck will operate from a thermostatsignal of 8–13 psi. With normalcalibration of the PVR, the unit will haveboth the heating and cooling deck atminimum with a thermostat signal of8 psi.

In order to have a unit minimum cfmand still have 0 cfm minimums on boththe heating and cooling deck, specialcalibration is required. The PVR has a“reset start” adjustment knob, whichallows the unit to be calibrated to aminimum cfm. This is achieved bycrossing over the thermostat ranges.Figure 17 illustrates this concept.

Figure 16–Typical VAV Dual-Duct Piping Diagram

Variable Air Volume Dual-DuctCalibration (3011)

N.O. Cooling ValveMin 0 cfm

Max 1000 cfm

N.O. Heating ValveMin 0 cfm

Max 1000 cfm

Unit Minimum 400 cfm

Max

Unit MinValve Min

4 7 9 128

TraneAn American Standard Companywww.trane.com

For more information contactyour local district office ore-mail us at [email protected]

Literature Order Number VAV-SVX02B-EN

File Number SV-TD-VAV000-SVX02B-EN-0302

Supersedes VAV-SVX02A-EN and VAV-IOM-6

Stocking Location La Crosse

Trane has a policy of continuous product and product data improvement and reserves the right to change designand specifications without notice. Only qualified technicians should perform installation and servicing ofequipment referred to in this publication.

Constant-Volume Single-Duct VAV ( VCV 3011)

This is used when a constant volume ofair is required to supply a zone. Athermostat is still often required tomodulate a reheat coil to maintaintemperature control. The thermostat isnever connected to the “T” port on thevolume regulator. The followingprocedure is used to calibrate this typeof unit with a PVR.

Constant-VolumeSingle-Duct VAV (VCV 3011)

1. Be sure there is 0 psi at the “T” port.2. Set LO thermostat adjustment knob to

desired unit cfm.

The unit will now modulate to thecalibrated cfm setting. See Figure 18 fortypical constant volume single-ductpiping diagram.

Figure 18–Typical Constant-Volume Single-Duct Piping Diagram

Tee(137.9)

20

S

(Reverse-Acting)T-Stat

Two-PipeRemote-Mounted

Electric Heater Terminal Box

(75.8)11

(86.2)12.5

14(96.5)

Stage 1

Stage 2

Stage 3

AirflowSafety Switch

P.E. Stage Switch(es)(Normally-Open)

(137.9)20

S

Flow Ring

Actuator

HI

LO H L

Regulator

B

MVolume

T

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